3.2L Engine & 3.5L V6 Engine: Removal & Installation Dodge Intrepid II

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable. Ensure area around fuel line and quick-connect fitting is clean. Place shop towel around fuel line. Squeeze retainer tabs together and pull quick-connect fitting off of fuel line. Retainer will stay on fuel line.

Installation

Ensure retainer is on quick-connect fitting or fuel line. Clean end of fuel line and retainer. Lubricate end of fuel line with 30W engine oil. Insert fuel line into disconnect fitting until retainer seats and a click is heard. To ensure proper fuel line connection, pull on fuel line and fitting.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9332-S29334826162000101800000). Disconnect negative battery cable from remote jumper terminal located at right strut tower. Mark hood at hinges, and remove hood. Remove wiper arms. Remove cowl covers and cowl support. Remove air inlet resonator and tube. Remove upper radiator crossmember. Disconnect hood release cable from hood latch. Disconnect cooling fan assembly connector, and remove cooling fan assembly.
2. Drain cooling system. Cover drive belts and/or pulleys to prevent contact with coolant. If coolant contacts belts and/or pulleys, flush both with clean water. Open radiator drain located at lower right side of radiator. DO NOT use pliers to open radiator drain. Remove coolant pressure bottle cap and open air bleed valve located on water outlet connector at front of engine. see scheme 6
3. Remove cylinder block drain plugs located below each exhaust manifold. Remove drive belts. Disconnect upper radiator hose at engine. Disconnect lower radiator hose at radiator. Disconnect engine oil and transaxle cooler lines at radiator. Remove power steering line bracket at left side of radiator. Remove fasteners attaching A/C condenser to radiator.
4. Remove radiator. Remove generator. Remove power steering pump bolts and, set pump aside. Remove A/C compressor bolts, and set compressor aside. Loosen, remove and discard "V" band clamps at right exhaust manifold. Remove front and rear support bracket fasteners attaching right catalytic converter down pipe.
5. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9332-S29334826162000101800000). Disconnect fuel lines. See «FUEL LINE QUICK-CONNECT FITTING»(ref-9332-S09838558542000101800000). Disconnect throttle and speed control cables. Disconnect coolant hoses at coolant pressure bottle. Disconnect all vacuum lines. Disconnect all engine ground straps. Remove upper intake manifold, and cover openings with tape. See «INTAKE MANIFOLD»(ref-9332-S35278080892000101800000).
6. Disconnect heater hoses. Remove rear throttle body support bracket. Remove fastener for water pipe located at transaxle-to-engine block bolt. Remove 4 upper transaxle-to-engine block bolts. Disconnect all electrical connectors.
7. Raise and support vehicle. Drain engine oil. Remove structural collar bolts from oil pan and transaxle. see scheme 25 Remove structural collar. Mark flex plate-to-torque converter position and remove torque converter bolts. Disconnect both transaxle cooler line brackets from engine.
8. Loosen, remove and discard "V" band clamps at left exhaust manifold. Loosen left catalytic converter down pipe band clamp, and front and rear support brackets.
9. Remove starter. Remove left and right engine mount bolts. Remove crankshaft position sensor. Remove 2 lower transaxle-to-engine block bolts. Lower vehicle. Attach hoist to engine. Support transaxle with a floor jack. Hoist engine from engine compartment.

Note. Replace motor mounts only if they are leaking.

To install, reverse removal procedure. Install NEW exhaust manifold "V" band clamps. DO NOT tighten engine mount bolts until all other engine block-to-transaxle housing bolts have installed. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Add 8 qts (7.8L) of 50/50 mix of MOPAR® Extended Life Coolant (or equivalent) and distilled water. Bleed cooling system. See COOLING SYSTEM BLEEDING .

Removal (Upper)

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove front engine compartment supports and upper radiator crossmember. On all models, remove air inlet resonator and tube. Remove throttle and speed control cables from throttle arm and bracket.
2. Disconnect Idle Air Control (IAC) motor, Intake Air Temperature (IAT), Manifold Absolute Pressure (MAP) sensor, Throttle Position Sensor (TPS) and Manifold Tuning Valve (MTV) connector, if equipped. Disconnect vapor hose, brake booster hose, speed control reservoir and Positive Crankcase Ventilation (PCV) hose.
3. Remove right and left upper intake manifold supports. Remove support brackets at intake manifold front corners and MTV. (Scheme 38) Loosen upper fastener attaching throttle body to support bracket. Remove clips attaching EGR tubes to intake manifold. Remove upper intake manifold bolts and manifold.

Removal (Lower)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9332-S29334826162000101800000). Drain cooling system. Cover drive belts and/or pulleys to prevent contact with coolant. If coolant contacts belts and/or pulleys, flush both with clean water. Open radiator drain located at lower right side of radiator.
2. DO NOT use pliers to open radiator drain. Remove coolant recovery reservoir cap, and open air bleed valve located on water outlet connector at front of engine. see scheme 6 Remove cylinder block drain plugs located below each exhaust manifold.
3. Remove upper intake manifold. Disconnect fuel injector and coolant temperature sensor connectors. Disconnect heater hose quick connect "T" from heater tube located at rear of manifold. Disconnect Fuel supply hose from fuel rail. See «FUEL LINE QUICK-CONNECT FITTING»(ref-9332-S09838558542000101800000).
4. Remove throttle body bracket-to-fuel rail bracket screw. Remove fuel rail bolts. Remove fuel rail and injectors as an assembly. Remove lower intake manifold bolts and manifold.

Clean and inspect mating surfaces. Gaskets can be reused if free from cuts or tears. Ensure fuel injectors and wiring harnesses are out of way. Tighten all bolts to specification and in correct sequence. See TORQUE SPECIFICATIONS. (Scheme 39)and (Scheme 40). To complete installation, reverse removal procedures.

Scheme 38

Scheme 39

Scheme 40

Remove upper intake manifold. See INTAKE MANIFOLD. Cover lower intake manifold openings. Disconnect ignition coil connectors and remove ignition coils. For right cylinder head cover remove A/C compressor mounting bolts and move compressor aside for cylinder head cover clearance. Remove valve cover bolts and valve covers. Inspect spark plug tube seals. (Scheme 41) If necessary, use a suitable pry tool and carefully remove tube seals.

Scheme 41

Clean cylinder head and valve cover mating surfaces. Replace valve cover gasket and spark plug tube seals as necessary. If replacing spark plug tube seals, position NEW seals so part number on seal faces cylinder head cover. Install seals using Spark Plug Tube Seal Installer (MB-998306). (Scheme 42) To complete installation, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 42

Removal (Right)

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove right hood side panel. On all models, raise and support vehicle.
2. Apply penetrating oil, and loosen band clamps at resonator connector. Support exhaust system with jack stand. Remove rubber isolators and exhaust system. Loosen catalytic converter pipe support attaching bolt at transaxle mount. Loosen A/C belt. Lower vehicle. Remove air inlet resonator and tube. Remove and discard "V" band clamp at exhaust manifold connector.
3. Remove A/C compressor bolts, and set compressor aside. Remove engine oil dipstick housing. Remove air conditioning compressor bracket. Disconnect O2S sensor connector and remove sensor. Remove heat shield bolts and heat shield. Remove exhaust manifold bolts and exhaust manifold.

Removal (Left)

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove left side panel. Remove Power Distribution Center (PDC) attaching screws and set PDC aside. Lift power steering reservoir from mounting bracket and set aside. On all models, raise and support vehicle.
2. Apply penetrating oil, and loosen band clamps at resonator connector. Support exhaust system with jack stand. Remove rubber isolators and exhaust system. Loosen catalytic converter pipe support bolt at transaxle mount. Lower vehicle. Remove and discard "V" band clamp at exhaust manifold connector. Remove electrical harness connector bracket. Disconnect O2 sensor connector and remove sensor. Remove heat shield bolts and heat shield. Remove exhaust manifold bolts and exhaust manifold.

Install NEW "V" band clamp. Install NEW "O" ring on engine oil dipstick tube. Install NEW EGR gaskets. Using NEW gasket, install manifold, and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9332-S29334826162000101800000). Disconnect negative battery cable from remote jumper terminal located at right strut tower. Drain cooling system. Cover drive belts and/or pulleys to prevent contact with coolant. If coolant contacts belts and/or pulleys, flush both with clean water.
2. Open radiator drain located at lower right side of radiator. DO NOT use pliers to open radiator drain. Remove coolant recovery reservoir cap, and open air bleed valve located on water outlet connector at front of engine. see scheme 6
3. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Using Crankshaft Pulley Holder (8191), hold crankshaft pulley and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley.
4. Remove timing belt covers. Remove camshaft sprockets. Remove intake manifold assembly. See «INTAKE MANIFOLD»(ref-9332-S35278080892000101800000). Remove cylinder head covers. See «CYLINDER HEAD COVERS»(ref-9332-S32418917572000101800000). Remove rear timing belt covers and water pump. Remove water pump "O" rings. Remove cylinder head bolts, and remove cylinder head.

1. Before installing head bolts, clean and lubricate threads with engine oil. Install head gasket over locating dowels. Ensure gasket is installed on correct side. (Scheme 43) Install cylinder head over dowels.
2. Tighten cylinder head bolts in sequence to specification. (Scheme 44) See «TORQUE SPECIFICATIONS»(ref-9332-S11039190512000101800000). To complete installation, reverse removal procedure.

Scheme 43

Scheme 44

Removal (Front)

Remove timing belt. See TIMING BELT. Using puller, remove crankshaft pulley. Tap out crankshaft dowel key. Use puller to remove crankshaft seal. (Scheme 45)

Removal (Rear)

Remove transaxle. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove drive plate. Pry out rear seal with screwdriver. DO NOT nick or scratch crankshaft flange seal surface or retainer bore.

Installation (Front)

Install crankshaft oil seal. Drive dowel key into crankshaft until only .047" (1.19 mm) protrudes. To complete installation, reverse removal procedure.

Note. Shaft seal surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.

Installation (Rear)

Place seal pilot on crankshaft. Using seal driver, seal driver handle, and plastic hammer, place seal over seal pilot and tap into place. Ensure seal is flush with housing surface. To complete installation, reverse removal procedure.

Scheme 45

Remove crankshaft rear oil seal. See CRANKSHAFT OIL SEAL . Remove oil pan. See OIL PAN . Remove rear crankshaft oil seal retainer bolts. Remove crankshaft oil seal retainer and gasket.

1. Clean mating surfaces and replace gasket as necessary. Install gasket and loosely assemble rear crankshaft oil seal retainer to engine block. Using oil pan bolts, attach crankshaft oil seal retainer aligner to oil pan rail. (Scheme 46) Ensure "3.2/3.5L" mark, stamped on crankshaft oil seal retainer aligner, is facing engine block.
2. While pushing rear crankshaft oil seal retainer toward aligner, tighten crankshaft oil seal retainer bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9332-S11039190512000101800000). Install crankshaft rear oil seal. Install oil pan.

Scheme 46

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Hold crankshaft pulley, and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley.
2. Remove lower timing belt cover located behind crankshaft pulley. Remove stamped steel cover. DO NOT remove reusable sealer from cover. If some cover sealer is missing, replace it with silicone rubber adhesive sealant. Remove left cast cover. CAUTION: Always rotate engine by turning crankshaft.
3. If timing belt is to be reused, mark timing belt direction of rotation. Rotate engine clockwise until crankshaft timing mark aligns with TDC mark on oil pump housing. see scheme 1 Ensure camshaft sprocket timing marks are between marks on rear covers. see scheme 1
4. Mark exact position of camshaft sprocket timing mark relative to 2 timing marks on rear timing cover. Remove timing belt tensioner and store it in vertical position, with plunger facing up. Remove timing belt.
5. Place timing belt tensioner in a soft-jaw vise. Ensure timing belt tensioner is placed in vise in same position as it is installed in engine. Slowly compress timing belt tensioner plunger. Timing belt tensioner bleed down will take about 5 minutes.
6. Insert lock pin through timing belt tensioner body and plunger. see scheme 4 Insure pin head is facing outside of engine when tensioner is reinstalled. Once pin is installed, tensioner must be stored with plunger facing up until tensioner is ready to be reinstalled.

1. Install timing belt by starting at crankshaft sprocket and working in a counterclockwise direction. Maintain tension on belt as it is positioned around tensioner pulley. Ensure camshaft sprocket marks are positioned between marks on cover.
2. Holding tensioner pulley against belt, install tensioner into housing and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9332-S11039190512000101800000). When tensioner is in place, pull retaining pin to allow tensioner to extend to pulley bracket. Ensure camshaft and crankshaft sprocket marks are aligned properly. see scheme 1
3. Rotate crankshaft 2 revolutions. Ensure camshaft and crankshaft sprocket timing marks are aligned properly. If timing marks are not aligned properly, repeat timing mark aligning procedure. If timing marks are still not aligned properly, check camshafts sprocket timing. See «CAMSHAFT SPROCKET TIMING PROCEDURE»(ref-9332-S04758485502000101800000) under ADJUSTMENTS.
4. To complete installation, reverse removal procedure. Start engine and allow to idle for about one minute. Increase engine speed to 1200-1500 RPM and run for about 5 minutes. This will help to bleed any air remaining in timing belt tensioner.

1. Remove valve covers. See «CYLINDER HEAD COVERS»(ref-9332-S32418917572000101800000). Identify rocker arm assembly and rocker arms before disassembly. (Scheme 47) Remove rocker arm assembly bolts. Remove rocker arm assembly.
2. Remove dowel pin using a 4-mm screw, nut, spacer and washer installed into pin. (Scheme 48) Tighten screw into pin, and run nut toward shaft against spacer. After pulling dowel out of shaft support, remove rockers and pedestals in order. Discard dowel pins.

Rotate camshaft until lobes are in a neutral position (little or no load to valves). (Scheme 50) Install rocker arm shaft assembly, ensuring identification marks face front of engine on left head, and toward rear of engine on right head. (Scheme 51) Install NEW retainer caps and dowel pins. Install oil feed bolt in correct location on rocker shaft retainer. Tighten bolts in sequence to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Remove cylinder head cover(s). See CYLINDER HEAD COVERS. Using suitable locking pliers, remove the tube from the cylinder head and discard tube. (Scheme 52)

Scheme 52

Clean area around spark plug with parts cleaner. Apply MOPAR® Stud and Bearing Mount to a new tube in a .118" (3 mm) wide area, approximately .039" (1 mm) from the bottom of the tube. Install sealer end of the tube into the cylinder head. Then carefully install the tube into the cylinder head using a hard wood block and mallet. Install the tube until it is seated into the bottom of the bore. Install cylinder head covers. See CYLINDER HEAD COVERS .

Camshaft can only be removed from rear of cylinder head. Remove camshaft sprocket. Remove cylinder head. See CYLINDER HEAD . Mark rocker arm and shaft assembly. Remove rocker arm and shaft assembly. See ROCKER ARM & VALVE LASH ADJUSTER . Remove rear camshaft cover and "O" ring from head. Remove camshaft from rear of cylinder head.

Lubricate camshaft journals and cam with clean engine oil. Install camshaft into cylinder head. Adjust camshaft sprockets. See CAMSHAFT SPROCKET TIMING PROCEDURE under ADJUSTMENTS. To complete installation, reverse removal procedure.

Scheme 53

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9332-S29334826162000101800000) . Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove air inlet resonator and tube. Remove upper intake manifold. See «INTAKE MANIFOLD»(ref-9332-S35278080892000101800000) . Remove valve covers. See «CYLINDER HEAD COVERS»(ref-9332-S32418917572000101800000) . Remove spark plugs. Remove rocker arm and shaft assembly. See «ROCKER ARM & VALVE LASH ADJUSTER»(ref-9332-S30460685722000101800000) . Rotate crankshaft clockwise to TDC of number one cylinders compression stroke.
2. Install a spark plug adapter in number one cylinder. Connect air hose to spark plug adapter. Apply 90-100 psi (6.3-7.0 kg/cm 2 ) of air to number one cylinder. Using valve compressor, compress valve spring and remove valve locks, retainer and valve spring. Remove valve stem seals. Follow same procedure on remaining cylinders. To install, reverse removal procedure.

1. Drain cooling system. Cover drive belts and/or pulleys to prevent contact with coolant. If coolant contacts belts and/or pulleys, flush both with clean water.
2. Open radiator drain located at lower right side of radiator. DO NOT use pliers to open radiator drain. Remove coolant recovery reservoir cap, and open air bleed valve located on water outlet connector at front of engine. see scheme 6 Remove timing belt. See «TIMING BELT & SPROCKETS»(ref-9332-S19944064852000101800000). Remove water pump bolts. Remove water pump and gasket.

Using NEW gasket, install water pump. To complete installation, reverse removal procedure. Tighten all bolts to specifications. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING .

Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove dipstick and dipstick housing. Raise and support vehicle. Drain engine oil. Remove structural collar located between oil pan and transaxle housing. Disconnect engine oil cooler line from oil pan. Disconnect transaxle oil cooler line clips. Remove oil pan bolts and nuts, and remove oil pan. Remove oil pan gasket.

1. Ensure oil pan and mating surfaces are clean. Inspect oil pan and timing belt cover gaskets and replace as necessary. Apply a 1/8" bead of silicone rubber adhesive sealant to oil pan-to-rear seal retainer mating surface and oil pan-to-oil pump housing. (Scheme 54)
2. Install oil pan gasket to engine block. Install oil pan. Install oil pan bolts and nuts. Install timing belt cover-to-pan bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-9332-S11039190512000101800000).
3. Install structural collar-to-oil pan vertical (position) bolts (No. 1) and tighten bolts to 10 INCH lbs. (1 N.m). (Scheme 55) Install structural collar-to-transaxle bolts (No. 2) and tighten bolts to 40 ft. lbs. (54 N.m).
4. Starting with center vertical (position) bolts (No. 1) and working outward, tighten bolts to 40 ft. lbs. (54 N.m). To complete installation, reverse removal procedure.

Scheme 54

Scheme 55

Note. It is not necessary to discharge air conditioning system when removing the radiator.

1. Disconnect negative cable from remote jumper terminal. WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
2. Drain cooling system.
3. Remove upper radiator crossmember.
4. Remove hose clamps and hoses from radiator.
5. Disconnect transmission hoses from cooler and plug off radiator.
6. Disconnect engine oil cooler lines (if equipped).
7. Disconnect the fan electrical connector.
8. Remove fan module.
9. Remove the air conditioning condenser attaching screws located at the front of the radiator.
10. Remove fastener attaching transmission cooler line bracket to left side of radiator.
11. Lift condenser upward, only enough to clear upper mounting clips; allow condenser to rest on lower radiator crossmember. It is not necessary to discharge the air conditioning system.
12. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.

1. Slide radiator down into position; seat the radiator assembly lower rubber isolators in the mounting holes provided in lower radiator support.
2. Attach air conditioning condenser to mounting clips on radiator. Install mounting screws and tighten to 5 N.m (45 in. lbs.).
3. Connect lower radiator hose and clamp.
4. Install transmission cooler line bracket and attaching fastener. Connect automatic transmission hoses; torque hose clamps to 2 N.m (18 in. lbs.).
5. Install fan module.
6. Connect fan motor electrical connector.
7. Connect engine oil cooler lines (if equipped). Torque lines to 18 N.m (160 in. lbs.).
8. Install upper radiator hose. Align hose so it does not interfere with the accessory drive belt or engine. Position hose clamp so it will not interfere with the hood liner.
9. Install upper radiator support crossmember.
10. Connect negative cable to remote jumper terminal.
11. Fill cooling system with coolant.
12. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for correct fluid levels.

Removal & Disassembly

1. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Hold crankshaft pulley, and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley.
2. Remove lower timing belt cover located behind crankshaft pulley. Remove stamped steel cover. DO NOT remove reusable sealer from cover. If some cover sealer is missing, replace it with silicone rubber adhesive sealant. Remove left cast cover.
3. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-9332-S19944064852000101800000) and «CRANKSHAFT OIL SEAL»(ref-9332-S38019514272000101800000) under REMOVAL & INSTALLATION. Remove oil pan. See «OIL PAN»(ref-9332-S06152891322000101800000) under REMOVAL & INSTALLATION. Remove oil pick-up tube and pick-up tube "O" ring. Remove oil pump bolts and oil pump.
4. To remove pressure relief valve, drill a 1/8" (3.175 mm) hole in relief valve retainer cap. Retainer cap is located at oil pan surface of timing belt cover, near oil pan stud. (Scheme 56)
5. Install a self-tapping screw into hole. Clamp screw in a vise. Support timing belt cover while lightly tapping on cover using soft-face hammer until retainer cap is removed.
6. Remove spring and pressure relief valve. Remove pump cover bolts and pump cover. Note direction of rotor installation. Remove inner and outer rotors. (Scheme 57)

Scheme 56

Scheme 57

Reassembly & Installation

To reassemble, reverse disassembly procedure. Install NEW relief valve retainer cap. Tighten cover bolts to specification. See TORQUE SPECIFICATIONS . Fill rotor cavity with engine oil before installation. To install, reverse removal procedure.